The 10 most common types of damage to pipe bridges - and how drones are revolutionising inspection
Why drones are the ideal solution for pipe bridge inspections
In modern industry, pipe bridges form a complex network of vital connections. As central infrastructure elements, they transport fluids, Gases and other media reliably through extensive industrial facilities. However, these critical systems are under constant strain: weather influences, thermal stress and mechanical effects are constantly putting the structures under strain.
The need for regular inspections is undisputed - but conventional methods reach their limits here. Industrial climbers, aerial work platforms or elaborate scaffolding solutions not only mean considerable costs and time expenditure, but also harbour significant safety risks for the inspection personnel.
Drone technology opens up completely new perspectives here: Flying systems equipped with high-resolution cameras and special sensors can easily reach areas that are difficult to access. They deliver detailed images and precise measurement data - and do so in a much shorter time and at lower cost, without exposing personnel to dangerous situations.
In this article, we analyse the ten most common types of damage to pipe bridges and show how modern drone inspections can detect them at an early stage. Find out how this innovative technology can replace traditional Industrial inspection and what specific advantages this will bring for your system.
1. corrosion under insulation (CUI)
Corrosion under insulation (CUI) is one of the most serious and at the same time most difficult types of damage to pipe bridges to detect. CUI occurs when moisture penetrates the insulation and attacks the surface of the pipes. This type of corrosion is often not noticed immediately as it remains hidden under the insulation, weakening the structure of the pipes unnoticed.
Causes:
- Ingress of water due to damaged or insufficient insulation
- Condensation caused by temperature cycles and humidity
- Damage to the insulation due to mechanical influences or UV radiation
Drones offer an innovative solution for detecting CUI at an early stage without having to remove the insulation. Equipped with thermographic sensors, drones can record temperature differences in the surface of the insulation that indicate moisture and therefore corrosion. This method saves considerable time and costs, as expensive dismantling and manual inspections are no longer necessary.
2. mechanical damage due to shocks and vibrations
Pipe bridges are subject to constant mechanical stress caused by vibrations and shocks caused by environmental influences such as wind, traffic or the operation of machinery. Over time, these mechanical effects can lead to structural weakening, which can manifest itself in the form of cracks, deformations or Material fatigue express.
Causes:
- Strong vibrations due to the operation of heavy machinery
- Wind and environmental influences
- Collisions with vehicles or other heavy equipment
Drones enable precise detection of the smallest cracks or deformations in pipelines and support structures. With high-resolution cameras and 3D scans, drones can monitor the integrity of the structure and detect even minimal damage that remains invisible to the human eye at an early stage. This reduces the risk of serious damage and production downtime.
3. weather-related damage due to UV radiation and extreme temperatures
Pipe bridges are constantly exposed to the elements of nature. UV radiation can damage protective layers and insulation over time, while extreme temperature fluctuations can fatigue the material and lead to cracks and deformation. These continuous environmental stresses contribute significantly to the deterioration of the infrastructure.
Causes:
- Direct sunlight and UV radiation that damages materials
- Extreme temperature changes that promote the expansion and contraction of materials
- Moisture and precipitation that favour corrosion
Drones offer the possibility of regular and comprehensive monitoring of pipe bridges by capturing high-resolution images and thermographic images of hard-to-reach areas. This data enables continuous monitoring of weather-related damage before it leads to serious problems.
4. foundation problems and subsidence
Settlement of the foundations or displacement of the ground are serious problems that can jeopardise the stability of the entire pipe bridge. These movements of the subsoil are often caused by soil changes, erosion or inadequately dimensioned foundations.
Causes:
- Soil movements due to erosion, flooding or soil compaction
- Inadequate foundation constructions
- Natural events such as earthquakes or heavy rainfall
Drones equipped with high-precision cameras and surveying technology can take aerial photographs of the foundation and quickly identify changes in the ground and structure. These images allow continuous monitoring and help to detect subsidence or displacement at an early stage before major damage occurs.
5. damage caused by vehicles or machinery
In industrial plants or near transport routes, pipe bridges can be damaged by collisions with vehicles, machines or even heavy equipment. These mechanical impacts can lead to deformations, fractures or cracks in the pipes and supporting structures.
Causes:
- Accidents or collisions with vehicles in confined industrial environments
- Crane or machine accidents that damage the bridges
- Mechanical impacts due to construction work or industrial processes
Drones can be used immediately after an accident or collision to assess damage to the pipe bridge from the air. They enable the damage to be recorded quickly and precisely without having to completely shut down the plant. This saves valuable time and reduces production downtime.
6. fatigue cracks due to repeated loading
Fatigue cracks occur as a result of cyclic loads to which pipe bridges are exposed due to temperature changes or repeated vibrations. These cracks develop gradually but worsen over time and can eventually lead to serious damage.
Causes:
- Repeated loads due to temperature cycles
- Vibrations from machines or pumps that continuously act on the structure
- Wind or weather loads that cause long-term weakening
Drones equipped with high-resolution cameras and crack monitoring technology can detect the smallest fatigue cracks in pipe bridges at an early stage. Regular inspections allow cracks to be recognised in good time before they lead to dangerous leaks or structural weaknesses.
7. damaged or worn insulation
The insulation of pipes and bridges protects the pipes from environmental influences, reduces energy losses and prevents moisture from penetrating the structure. Over time, however, this insulation can be affected by UV radiation, mechanical damage or simple wear and tear.
Causes:
- Ageing of the insulation material due to UV radiation and extreme temperatures
- Mechanical damage due to vibrations or impacts
- Moisture penetrating through cracks in the insulation
Drones and thermographic sensors can be used to quickly identify damaged or worn insulation before major problems such as CUI occur. This regular monitoring makes it possible to maintain the efficiency of the insulation and minimise repairs in the long term.
8. corrosion caused by aggressive chemicals in the ambient air
In industrial environments, the air can often contain aggressive chemicals that attack the surface of the pipes and accelerate corrosion. This type of chemical corrosion occurs particularly in heavily industrialised areas and significantly impairs the service life of pipe bridges.
Causes:
- High concentrations of sulphur or nitrogen oxides in the air
- Direct contact with chemicals through industrial processes
- Chemically aggressive environments in refineries or chemical plants
Drones equipped with sensors to detect corrosion can be used regularly to monitor the condition of pipe bridges and identify damage at an early stage. These regular inspections prevent major corrosion damage and extend the service life of the structure.
9. leaks in connections, seals and expansion joints
Joints and seals are particularly susceptible to wear and material fatigue. Leaks at these connections can cause liquids or gases to leak, which not only impairs the efficiency of the system, but also poses considerable safety and environmental risks.
Causes:
- Thermal or mechanical loads that weaken connections
- Ageing and wear of sealing materials
- Incorrect assembly or insufficiently dimensioned seals
Drones can carry out inspections in hard-to-reach places and use thermal imaging cameras and high-resolution sensors to detect leaks in connections and seals. This allows problems to be rectified in good time before they lead to costly breakdowns or environmental damage.
10. material fatigue due to temperature fluctuations
- Regular and extreme temperature cycles
- Expansion and contraction of the material due to seasonal temperature differences
- Material ageing due to thermal loads
Conclusion
The inspection of pipe bridges is a key element of modern industrial plants - it not only ensures the functionality of critical infrastructure, but also makes a significant contribution to environmental protection, operational safety and occupational health and safety. While traditional inspection methods struggle with significant challenges - from high-risk work at height to costly plant shutdowns - drone technology opens up new, efficient ways of monitoring plants.
The use of modern inspection drones transforms several aspects at once:
Occupational safety: Instead of sending people to dangerous heights or areas that are difficult to access, drones carry out detailed inspections - precisely, reliably and without personal risk.
Operating efficiency: Faster inspection cycles and minimised downtimes significantly increase system availability. The high-resolution image data obtained also enables more precise maintenance planning.
Environmental protection: By detecting corrosion damage, material fatigue or potential leaks at an early stage, environmental risks can be proactively minimised. This actively supports companies in achieving their sustainability goals.
Drone-based inspections of pipe bridges therefore not only represent the current state of the art - they are an important step towards a safer, more efficient and more sustainable industrial future.
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